Apparatus for Mixing Regenerated and Carbonized Catalyst

ABSTRACT

An apparatus for mixing regenerated and carbonized catalyst involves obstructing upward flow of catalyst by one or more baffles between a catalyst inlet and a feed distributor. Each catalyst stream may be passed to opposite sides of a riser. Baffles obstruct upward flow to effect mixing of regenerated and carbonized catalyst to obtain a more uniform temperature and catalyst mixture before contacting the feed.

BACKGROUND OF THE INVENTION

The invention relates to an apparatus for mixing carbonized andregenerated catalyst. A field of the invention may be the field of fluidcatalytic cracking (FCC).

FCC is a hydrocarbon conversion process accomplished by contactinghydrocarbons in a fluidized reaction zone with a catalyst composed offinely divided particulate material. The reaction in catalytic cracking,as opposed to hydrocracking, is carried out in the absence ofsubstantial added hydrogen or the consumption of hydrogen. As thecracking reaction proceeds substantial amounts of highly carbonaceousmaterial referred to as coke are deposited on the catalyst to providecoked or carbonized catalyst. This carbonized catalyst is often referredto as spent catalyst. However, this term may be misconstrued because thecarbonized catalyst still has significant catalytic activity. Vaporousproducts are separated from carbonized catalyst in a reactor vessel.Carbonized catalyst may be subjected to stripping over an inert gas suchas steam to strip entrained hydrocarbonaceous gases from the carbonizedcatalyst. A high temperature regeneration with oxygen within aregeneration zone operation burns coke from the carbonized catalystwhich may have been stripped.

Although the carbonized catalyst carries coke deposits it may still haveactivity. U.S. Pat. No. 3,888,762 discloses mixing carbonized andregenerated catalyst for contact with the hydrocarbon feed. Theregenerated catalyst may be in the range of 593° to 760° C. (1100° to1400° F.) and the carbonized catalyst may be in the range of 482° to621° C. (900° to 1150° F.). U.S. Pat. No. 5,597,537 discloses mixing thecarbonized and regenerated catalyst in a blending vessel or mixingchamber to allow the regenerated and carbonized catalyst to reach atemperature equilibrium before contacting the hydrocarbon feed. A mixedcatalyst with more uniform temperature avoids hot spots that cangenerate nonselective cracking to reduce the value of the producthydrocarbons.

Improved apparatus and processes are sought in the mixing of carbonizedand regenerated catalyst.

SUMMARY OF THE INVENTION

We have found that the mixing chamber for process units that aredesigned to process large amounts of feed can become very large whichadds to the capital cost and requires more catalyst inventory to fillthe increased volume added by the chamber to an entire process unit.However, we have discovered that carbonized and regenerated catalyst canbe mixed in the base of a reactor riser by use of at least one bafflebelow the feed distributor to achieve substantial temperatureequilibration before the catalyst contacts the feed without the need fora mixing chamber. We have also found that mixing catalyst is improved bypassing carbonized and regenerated catalyst to opposite sides of theriser.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic, elevational view of an FCC unit incorporating thepresent invention.

FIG. 2 is a perspective view of a lower partial section of FIG. 1.

FIG. 3 is a sectional view of FIG. 2 taken at segment 3-3.

DETAILED DESCRIPTION OF THE INVENTION

The apparatus of the present invention is for contacting catalyst with ahydrocarbon feed or for mixing regenerated catalyst and carbonizedcatalyst for contact with a hydrocarbon feed. The present invention maybe useful in any solids-gas contacting equipment. However, readyusefulness is found in an FCC unit. FIG. 1 shows an FCC unit 8 thatincludes a reactor vessel 20 and a regenerator vessel 50. A regeneratorcatalyst conduit 12 transfers regenerated catalyst from the regeneratorvessel 50 at a rate regulated by a control valve 14 to a reactor riser10 through a regenerated catalyst inlet 15. A fluidization medium suchas steam from a nozzle 16 urges a stream of catalyst upwardly throughthe riser 10 at a relatively high density. A plurality of feeddistributors 18 inject feed across the flowing stream of catalystparticles to distribute hydrocarbon feed to the riser 10. The feeddistributors 18 are located on a frustum 19 of the riser. Uponcontacting the hydrocarbon feed with catalyst in the reactor riser 10the heavier hydrocarbon feed cracks to produce lighter gaseoushydrocarbon product while coke is deposited on the catalyst particles toproduce carbonized catalyst.

A conventional FCC feedstock and higher boiling hydrocarbon feedstockare suitable feeds. The most common of such conventional feedstocks is a“vacuum gas oil” (VGO), which is typically a hydrocarbon material havinga boiling range of from 343° to 552° C. (650 to 1025° F.) prepared byvacuum fractionation of atmospheric residue. Such a fraction isgenerally low in coke precursors and heavy metal contamination which canserve to contaminate catalyst. Heavy hydrocarbon feedstocks to whichthis invention may be applied include heavy bottoms from crude oil,heavy bitumen crude oil, shale oil, tar sand extract, deasphaltedresidue, products from coal liquefaction, atmospheric and vacuum reducedcrudes. Heavy feedstocks for this invention also include mixtures of theabove hydrocarbons and the foregoing list is not comprehensive. It isalso contemplated that lighter recycle or previously cracked feeds suchas naphtha may be a suitable feedstock.

The reactor vessel 20 is in downstream communication with the riser 10.In the reactor vessel, the carbonized catalyst and the gaseous productare separated. The resulting mixture of gaseous product hydrocarbons andcarbonized catalyst continues upwardly through the riser 10 into thereactor vessel 20 in which the carbonized catalyst and gaseous productare separated. A pair of disengaging arms 22 may tangentially andhorizontally discharge the mixture of gas and catalyst from a top of theriser 10 through one or more outlet ports 24 (only one is shown) into adisengaging vessel 26 that effects partial separation of gases from thecatalyst. A transport conduit 28 carries the hydrocarbon vapors,including stripped hydrocarbons, stripping media and entrained catalystto one or more cyclones 30 in the reactor vessel 20 which separatescarbonized catalyst from the hydrocarbon gaseous stream. The disengagingvessel 26 is partially disposed in the reactor vessel 20 and can beconsidered part of the reactor vessel 20. A collection plenum 34 in thereactor vessel 20 gathers the separated hydrocarbon gaseous streams fromthe cyclones 30 for passage to an outlet nozzle 36 and eventually into afractionation recovery zone (not shown). Diplegs 38 discharge catalystfrom the cyclones 30 into a lower bed 29 in the reactor vessel 20. Thecatalyst with adsorbed or entrained hydrocarbons may eventually passfrom the lower bed 29 into an optional stripping section 40 across ports42 defined in a wall of the disengaging vessel 26. Catalyst separated inthe disengaging vessel 26 may pass directly into the optional strippingsection 40 via a bed 41. A fluidizing conduit 45 delivers inertfluidizing gas, typically steam, to the stripping section 40 through afluidizing distributor 46.The stripping section 40 contains baffles 43,44 or other equipment to promote contacting between a stripping gas andthe catalyst. The stripped carbonized catalyst leaves the strippingsection 40 of the disengaging vessel 26 of the reactor vessel 20 with alower concentration of entrained or adsorbed hydrocarbons than it hadwhen it entered or if it had not been subjected to stripping. A firstportion of the carbonized catalyst leaves the disengaging vessel 26 ofthe reactor vessel 20 through a spent catalyst conduit 48 and passesinto the regenerator vessel 50 at a rate regulated by a slide valve 51.A second portion of the carbonized catalyst that has been coked inreactor riser 10 leaves the disengaging vessel 26 of the reactor vessel20 and is passed through a carbonized catalyst conduit 52 back to theriser 10 at a rate regulated by a control valve 53. The carbonizedcatalyst conduit 52 is in downstream communication with the reactorvessel 20 and intersects the riser 10 at a carbonized catalyst conduitintersection 94. The carbonized catalyst conduit 52 is in downstreamcommunication with the outlet port 24 of the riser 10 and in upstreamcommunication with a carbonized catalyst inlet 97 to the riser 10.

The riser 10 of the FCC process is maintained at high temperatureconditions which generally include a temperature above about 425° C.(797° F.). In an embodiment, the reaction zone is maintained at crackingconditions which include a temperature of from about 480° to about 621°C. (8960 to 1150° F.) at the riser outlet port 24 and a pressure of fromabout 69 to about 517 kPa (ga) (10 to 75 psig) but typically less thanabout 275 kPa (ga) (40 psig). The catalyst-to-oil ratio, based on theweight of catalyst and feed hydrocarbons entering the bottom of theriser, may range up to 30:1 but is typically between about 4:1 and about10:1 and may range between 7:1 and 25:1. Hydrogen is not normally addedto the riser, although hydrogen addition is known in the art. Steam maybe passed into the riser 10 and reactor vessel 20 equivalent to about2-35 wt-% of feed. Typically, however, the steam rate will be betweenabout 2 and about 7 wt-% for maximum gasoline production and about 10 toabout 15 wt-% for maximum light olefin production. The average residencetime of catalyst in the riser may be less than about 5 seconds. The typeof catalyst employed in the process may be chosen from a variety ofcommercially available catalysts. A catalyst comprising a zeoliticmaterial such as Y Zeolite is preferred, but the older style amorphouscatalysts can be used if desired. Additionally, shape-selectiveadditives such as ZSM-5 may be included in the catalyst composition toincrease light olefin production.

The regenerator vessel 50 is in downstream communication with thereactor vessel 20. In the regenerator vessel 50, coke is combusted fromthe portion of carbonized catalyst delivered to the regenerator vessel50 by contact with an oxygen-containing gas such as air to provideregenerated catalyst. The regenerator vessel 50 may be a combustor typeof regenerator, which may use hybrid turbulent bed-fast fluidizedconditions in a high-efficiency regenerator vessel 50 for completelyregenerating carbonized catalyst. However, other regenerator vessels andother flow conditions may be suitable for the present invention. Thespent catalyst conduit 48 feeds carbonized catalyst to a first or lowerchamber 54 defined by outer wall 56 through a spent catalyst inlet chute62. The carbonized catalyst from the reactor vessel 20 usually containscarbon in an amount of from 0.2 to 2 wt-%, which is present in the formof coke. Although coke is primarily composed of carbon, it may containfrom 3 to 12 wt-% hydrogen as well as sulfur and other materials. Anoxygen-containing combustion gas, typically air, enters the lowerchamber 54 of the regenerator vessel 50 through a conduit 64 and isdistributed by a distributor 66. As the combustion gas enters the lowerchamber 54, it contacts carbonized catalyst entering from chute 62 andlifts the catalyst at a superficial velocity of combustion gas in thelower chamber 54 of perhaps at least 1.1 m/s (3.5 ft/s) under fastfluidized flow conditions. In an embodiment, the lower chamber 54 mayhave a catalyst density of from 48 to 320 kg/m³ (3 to 20 lb/ft³) and asuperficial gas velocity of 1.1 to 2.2 m/s (3.5 to 7 ft/s). The oxygenin the combustion gas contacts the carbonized catalyst and combustscarbonaceous deposits from the catalyst to at least partially regeneratethe catalyst and generate flue gas.

In an embodiment, to accelerate combustion of the coke in the lowerchamber 54, hot regenerated catalyst from a dense catalyst bed 59 in anupper or second chamber 70 may be recirculated into the lower chamber 54via an external recycle catalyst conduit 67 regulated by a control valve69. Hot regenerated catalyst enters the lower chamber 54 through aninlet chute 63. Recirculation of regenerated catalyst, by mixing hotcatalyst from the dense catalyst bed 59 with relatively coolercarbonized catalyst from the spent catalyst conduit 48 entering thelower chamber 54, raises the overall temperature of the catalyst and gasmixture in the lower chamber 54.

The mixture of catalyst and combustion gas in the lower chamber 54ascend through a frustoconical transition section 57 to the transport,riser section 60 of the lower chamber 54. The riser section 60 defines atube which is preferably cylindrical and extends preferably upwardlyfrom the lower chamber 54. The mixture of catalyst and gas travels at ahigher superficial gas velocity than in the lower chamber 54. Theincreased gas velocity is due to the reduced cross-sectional area of theriser section 60 relative to the cross-sectional area of the lowerchamber 54 below the transition section 57. Hence, the superficial gasvelocity may usually exceed about 2.2 m/s (7 ft/s). The riser section 60may have a lower catalyst density of less than about 80 kg/m³ (5lb/ft³).

The regenerator vessel 50 also includes an upper or second chamber 70.The mixture of catalyst particles and flue gas is discharged from anupper portion of the riser section 60 into the upper chamber 70.Substantially completely regenerated catalyst may exit the top of thetransport, riser section 60, but arrangements in which partiallyregenerated catalyst exits from the lower chamber 54 are alsocontemplated. Discharge is effected through a disengaging device 72 thatseparates a majority of the regenerated catalyst from the flue gas. Inan embodiment, catalyst and gas flowing up the riser section 60 impact atop elliptical cap 65 of the riser section 60 and reverse flow. Thecatalyst and gas then exit through downwardly directed discharge outlets73 of disengaging device 72. The sudden loss of momentum and downwardflow reversal cause a majority of the heavier catalyst to fall to thedense catalyst bed 59 and the lighter flue gas and a minor portion ofthe catalyst still entrained therein to ascend upwardly in the upperchamber 70. Cyclones 82, 84 further separate catalyst from ascending gasand deposits catalyst through diplegs 85, 86 into dense catalyst bed 59.Flue gas exits the cyclones 82, 84 and collects in a plenum 88 forpassage to an outlet nozzle 89 of regenerator vessel 50 and perhaps intoa flue gas or power recovery system (not shown). Catalyst densities inthe dense catalyst bed 59 are typically kept within a range of fromabout 640 to about 960 kg/m³ (40 to 60 lb/ft³). A fluidizing conduit 74delivers fluidizing gas, typically air, to the dense catalyst bed 59through a fluidizing distributor 76. In a combustor-style regenerator,approximately no more than 2% of the total gas requirements within theprocess enter the dense catalyst bed 59 through the fluidizingdistributor 76. In this embodiment, gas is added here not for combustionpurposes but only for fluidizing purposes, so the catalyst will fluidlyexit through the catalyst conduits 67 and 12. The fluidizing gas addedthrough the fluidizing distributor 76 may be combustion gas. In the casewhere partial combustion is effected in the lower chamber 54, greateramounts of combustion gas will be fed to the upper chamber 70 throughfluidizing conduit 74.

From about 10 to 30 wt-% of the catalyst discharged from the lowerchamber 54 is present in the gases above the outlets 73 from the risersection 60 and enter the cyclones 82, 84. The regenerator vessel 50 maytypically require 14 kg of air per kg of coke removed to obtain completeregeneration. When more catalyst is regenerated, greater amounts of feedmay be processed in a conventional reactor riser. The regenerator vessel50 typically has a temperature of about 594 to about 704° C. (1100 to1300° F.) in the lower chamber 54 and about 649 to about 760° C. (1200to 1400° F.) in the upper chamber 70. The regenerated catalyst conduit12 is in downstream communication with the regenerator vessel 50 andintersects the riser 10 at a regenerated catalyst conduit intersection90. Regenerated catalyst from dense catalyst bed 59 is transportedthrough regenerated catalyst conduit 12 from the regenerator vessel 50back to the reactor riser 10 through the control valve 14 where it againcontacts feed as the FCC process continues.

A regenerated catalyst baffle 92 is disposed in the riser 10 above theregenerated catalyst inlet 15 and below the feed distributors 18proximate to the regenerated catalyst conduit intersection 90. Theregenerated catalyst baffle 92 partially obstructs upward flow of theregenerated catalyst in the riser 10 to mix the regenerated catalyst inthe riser before it contacts the hydrocarbon feed injected from feeddistributors 18 into the riser 10. In an embodiment, the regeneratedcatalyst baffle 92 is disposed in the riser 10 at or above theregenerated catalyst conduit intersection 90. In a further embodiment,the regenerated catalyst baffle 92 is disposed in the riser 10 above theregenerated catalyst inlet 15.

We have also found when a stream of carbonized catalyst and a stream ofregenerated catalyst are both fed into the riser 10; they tend not tomix before contacting the hydrocarbon feed. Accordingly, the feed canencounter catalyst at varying temperatures resulting in non-selectivecracking to a composition with relatively more undesirable products. Ina preferred embodiment, to ensure mixing between the carbonized catalystand the regenerated catalyst, in addition to the aforementionedregenerated catalyst baffle 92, a second, carbonized catalyst baffle 96is disposed in the riser above the carbonized catalyst inlet 97 andbelow the feed distributors 18 proximate to the carbonized catalystconduit intersection 94. The carbonized catalyst baffle 96 in the riser10 partially obstructs upward flow of the carbonized catalyst to effectmixing to provide mixed catalyst of carbonized and regenerated catalyst.In an embodiment, the carbonized catalyst baffle 96 is disposed in saidriser at or above said carbonized catalyst conduit intersection 94.

The carbonized catalyst baffle 96 and the regenerated catalyst baffle 92operate to mix the hot regenerated catalyst and the cooler carbonizedcatalyst that has not undergone a hot regeneration cycle in theregenerator vessel 50. In describing the mixing operation of the baffles92 and 96, the baffles will be referred to as lower and upper bafflesand lower and upper catalyst conduits which will depend upon the desiredarrangement. The arrangement in the drawings has the regeneratedcatalyst conduit 12 as the upper catalyst conduit, the carbonizedcatalyst conduit 52 as the lower catalyst conduit, the regeneratedcatalyst baffle 92 as the upper baffle, and the carbonized catalystbaffle 96 as the lower baffle. The lower baffle 92, 96 collects therising fluidizing gas from nozzle 16 and forces the catalyst from thelower catalyst conduit 12, 52 in a horizontal direction. The inflowingcatalyst and fluidizing gas are directed to the opposing wall of theriser 10 and ascend vertically to contact the catalyst fed from theupper catalyst conduit 52, 12. The upper baffle 96, 92 preferably abovethe upper catalyst conduit intersection 90, 94 with the riser 10 notonly causes the two catalyst streams to blend horizontally, but alsoinduces additional mixing through the formation of a circular blendingeddy between the rising fluidizing gas with catalyst and the catalyststream flowing from the upper catalyst conduit. The mixing is effectedto bring the respective catalyst streams closer to uniform temperatureand homogeneous composition before encountering the hydrocarbon feed,which will result in cracking to more desirable products.

In an embodiment, the regenerated catalyst conduit intersection 90 isabove the carbonized catalyst conduit intersection 94 and theregenerated catalyst inlet 15 is above the carbonized catalyst inlet 97.Steam can have a dealuminating effect on the zeolitic catalyst and thisdealuminating effect increases proportionally with temperature. Bybringing the cooler carbonized catalyst into the riser between thefluidizing gas which is typically steam from nozzle 16 and theregenerated catalyst from regenerated catalyst conduit 12, thecarbonized catalyst has an opportunity to cool the regenerated catalystbefore the regenerated catalyst stream encounters the steam.Consequently, the regenerated catalyst encounters the steam only at areduced temperature at which the dealuminating effect is minimized.

FIG. 2 is a perspective view of the lower cut-away section of the riser10. In an embodiment, the regenerated catalyst baffle 92 is above theregenerated catalyst inlet 15. Additionally, in an embodiment, thecarbonized catalyst baffle 96 is above the carbonized catalyst inlet 97.In an embodiment, the regenerated catalyst baffle 92 is an extension ofthe regenerated catalyst conduit 12. Moreover, in an embodiment, thecarbonized catalyst baffle 96 is an extension of the carbonized catalystconduit 52. In an embodiment, a horizontal component of the regeneratedcatalyst baffle 92 extends into the riser 10 by at least one-half of thediameter of the riser. In an additional embodiment, a horizontalcomponent of the regenerated catalyst baffle 92 extends into the riser10 by no more than two-thirds of the diameter of the riser. In a furtherembodiment, a horizontal component of the carbonized catalyst baffle 96extends into the riser 10 by at least one-half of the diameter of theriser. In a still further embodiment, a horizontal component of thecarbonized catalyst baffle 96 extends into the riser 10 by no more thantwo-thirds of the diameter of the riser. The baffles 92 and 96 whichtake the embodiment of an extension of the conduit into the riser 10define only a semi-cylindrical extension of the conduit, and each baffleis continuous with only the top half of the conduit. The bottom half ofthe conduit would not be continuous with the baffle. The top half of theconduit may actually extend into the riser 10 or the baffle 92, 96 maybe welded to the interior wall of the riser at the intersection of theconduit with the riser 10. The horizontal component of both baffles mayextend just over a center line A of the riser 10. The inner ends of eachbaffle 92, 96 may be cut in a vertical plane. The regenerated catalystconduit intersection 90 and the carbonized catalyst conduit intersection94 are located at the top-most point where the respective conduitsintersect the riser 10. In an embodiment, the regenerated catalystconduit intersection 90 with the riser is about 0.5 to about 2.0 riserdiameters above the carbonized catalyst conduit intersection 94 with theriser. Preferably, the regenerated catalyst conduit intersection 90 withthe riser is about one riser diameter above the carbonized catalystconduit intersection 94. Additionally, the feed distributors 18 may belocated on the frustum 19 about 1 to about 3 riser diameters above theupper catalyst conduit intersection which in FIG. 2 is the regeneratedcatalyst conduit intersection 90. In an embodiment the feed distributors18 are at least 3 riser diameters above the upper catalyst conduitintersection but no higher than a top of the frustum 19. The carbonizedcatalyst conduit 52 may approach the riser 10 at an acute angle a ofabout 30 to about 55 degrees and preferably between about 40 and about50 degrees at the carbonized catalyst conduit intersection 94. Theregenerated catalyst conduit 12 may approach the riser at an acute anglethat is less than that of the carbonized catalyst conduit. Theregenerated catalyst conduit 12 may approach the riser at an acute angleβ of about 15 to about 50 degrees and preferably about 25 to about 35degrees at the regenerated catalyst conduit intersection 90. Hence, theregenerated catalyst in the regenerated catalyst conduit 12 is fed tothe riser 10 at an acute angle β of about 15 to about 50 degrees andpreferably about 25 to about 35 degrees with respect to the riser 10.Other approach angles may be suitable. The baffles 92 and 96 may definethe respective acute angle a and P which the corresponding catalystconduit 12, 52 defines with the riser 10. The nozzle 16 may extend intoa lower inlet, which in the embodiment of FIG. 2 is the carbonized inlet97, to a height that is higher than a midpoint of the inlet.

Best mixing is effected with the carbonized catalyst conduit 52 and theregenerated catalyst conduit 12 approach the riser on opposite sides.FIG. 3 is a cross-section of FIG. 2 taken at segment 3-3. Carbonizedcatalyst conduit 52 joins the riser 10 at carbonized catalyst conduitintersection 94. The carbonized catalyst baffle 96 extends into theriser from a location proximate to the carbonized catalyst conduitintersection 94 and in FIG. 3 is continuous with the top half of thecarbonized catalyst conduit 52. A horizontal component of carbonizedcatalyst baffle 96 extends into the riser 10 over half of a riserdiameter as shown in phantom. Regenerated catalyst conduit 12 joins theriser 10 at regenerated catalyst conduit intersection 90. Theregenerated catalyst conduit is typically larger in diameter than thecarbonized catalyst conduit because it typically carries a greater flowrate of catalyst. The regenerated catalyst baffle 92 extends into theriser from a location proximate to the regenerated catalyst conduitintersection 90 and in FIG. 3 is continuous with the top half of theregenerated catalyst conduit 12. A horizontal component of regeneratedcatalyst baffle 92 extends into the riser 10 over half a riser diameterand preferably is above the carbonized catalyst baffle 96. Refractorylining may be used in the riser 10 to protect from abrasion but is notshown in the drawings. In FIG. 3, the regenerated catalyst conduit 12and the carbonized catalyst conduit 52 define a horizontal obtuse angley of at least about 135 degrees at respective intersections 90, 94 andthe baffles 92, 96 may follow the same angle. In FIG. 3, the angle ydefined by the regenerated catalyst conduit 12 and the carbonizedcatalyst conduit at the respective intersections 90, 94 is 180 degrees.

EXAMPLE

Computational Fluid Dynamic (CFD) modeling was used to evaluate theexpected performance of an arrangement in which a carbonized catalystconduit and a regenerated catalyst conduit both feed catalyst to a riserwithout any baffles. In the modeling, the regenerated catalyst inlet wasbelow the spent catalyst inlet. The carbonized catalyst was assumed tohave a coke on catalyst of 1 wt-%, a catalyst flow rate of 23,092,921lb/h (10,474,771 kg/h), a gas flow rate of 11,112, lb/h (5,040 kg/h) anda temperature of 1020° F. (549° C.). The regenerated catalyst wasassumed to have a coke on catalyst of 0 wt-%, a catalyst flow rate of23,092,921 lb/h (10,474,771 kg/h), a gas flow rate of 11,112, lb/h(5,040 kg/h) and a temperature of 1367° F. (742° C.). The steamdistributor was assumed to provide steam at a gas flow rate of 90,701lb/h (41,141 kg/h) and a temperature of 310° F. (154° C.). Catalystdensity was assumed to be 90 lb/ft³ (1442 kg/m³), and the gas wasassumed to have a density of 0.106 lb/ft³ (1.7 kg/m³) and a viscosity of0.036 cP. The heat capacity was assumed to be 0.24 Btu/lb-° F. (1kJ/kg-° K.) for the gas and 0.275 Btu/lb-° F. (1.15 kJ/kg-° K.) for thecatalyst.

Results showed that each catalyst stream essentially stayed on the sideof the riser to which it was fed and the fluidizing steam injected at abottom of the riser flowed upwardly between the two streams in a centralregion of lower density. The fluidizing steam operated as a barrier toprevent the two catalyst streams from mixing. The modeling revealed acalculated temperature differential of a 59 C° (106° F.) between thehottest and coolest regions in the riser at an elevation of about 4meters above an intersection of the carbonized catalyst conduit with theriser. This temperature differential indicated a severe maldistributionof carbonized catalyst across the riser which would result in a pooryield performance.

CFD modeling was subsequently performed with riser with baffles of thepresent invention. A baffle was located above the inlet to the riserfrom each catalyst conduit. The baffles modeled were extensions of thetop semi-cylindrical half of the catalyst conduits into the riser inaccordance with an embodiment of the present invention. The modelingrevealed a calculated temperature differential for the present inventionof only a 9° C. (17° F.) between hottest and coolest regions in theriser at an elevation of about 4 meters above an intersection of thecarbonized catalyst conduit with the riser. This temperaturedifferential indicates good distribution between catalyst streams. Theresulting differential for coke on catalyst is 0.054 wt-% at the sameelevation. At an elevation of about 7 meters above an intersection ofthe carbonized catalyst conduit with the riser, which corresponds toabout 3 riser diameters, the temperature differential was calculated tobe about 6° C. (10° F.) and the differential for coke on catalyst wasabout 0.032 wt-%. Consequently, adequate mixing of carbonized andregenerated catalyst can be achieved without the need for a separateblending vessel.

1. An apparatus for contacting regenerated catalyst with a hydrocarbonfeed, said apparatus comprising: a riser in which said hydrocarbon feedis contacted with catalyst particles to catalytically crack hydrocarbonsin said hydrocarbon feed to produce a gaseous product of lighterhydrocarbons and carbonized catalyst; a feed distributor fordistributing hydrocarbon feed to said riser; a reactor vessel incommunication with said riser, said reactor vessel for separating thecarbonized catalyst and the gaseous product; a regenerator vessel incommunication with said reactor vessel, said regenerator vessel forcombusting carbon from the carbonized catalyst with an oxygen-containinggas to provide regenerated catalyst; a regenerated catalyst conduit incommunication with said regenerator; said regenerated catalyst conduitintersecting said riser at a regenerated catalyst conduit intersectionfor transporting regenerated catalyst to said riser; a regeneratedcatalyst baffle in said riser below said feed distributor and proximateto said regenerated catalyst conduit intersection for mixing theregenerated catalyst.
 2. The apparatus of claim 1 wherein saidregenerated catalyst conduit defines a regenerated catalyst inlet tosaid riser and said regenerated catalyst baffle is disposed above saidregenerated catalyst inlet.
 3. The apparatus of claim 1 wherein saidregenerated catalyst baffle is an extension of said regenerated catalystconduit.
 4. The apparatus of claim 1 wherein a horizontal component ofsaid regenerated catalyst baffle extends into the riser by at leastone-half of the diameter of the riser.
 5. The apparatus of claim 1further including a carbonized catalyst conduit in communication withsaid reactor vessel, said carbonized catalyst conduit intersecting saidriser at a carbonized catalyst conduit intersection for transportingcarbonized catalyst to said riser and further including a carbonizedcatalyst baffle proximate to the said carbonized catalyst conduitintersection.
 6. The apparatus of claim 1 wherein said regeneratedcatalyst conduit intersection is above said carbonized catalyst conduitintersection.
 7. The apparatus of claim 1 wherein said regeneratedcatalyst conduit and said carbonized catalyst conduit define ahorizontal angle of at least about 135 degrees at a respective one ofsaid regenerated catalyst conduit intersection and said carbonizedcatalyst conduit intersection.
 8. The apparatus of claim 1 wherein saidregenerated catalyst conduit and said riser define a vertical angle ofabout 25 to about 35 degrees at the carbonized catalyst conduitintersection.
 9. An apparatus for mixing regenerated catalyst andcarbonized catalyst for contact with a hydrocarbon feed, said apparatuscomprising: a riser in which said hydrocarbon feed is contacted withcatalyst particles to catalytically crack hydrocarbons in saidhydrocarbon feed to produce a gaseous product of lighter hydrocarbonsand carbonized catalyst; a feed distributor for distributing hydrocarbonfeed to said riser; a reactor vessel in communication with said riser,said reactor vessel for separating the carbonized catalyst and thegaseous product; a regenerator vessel in communication with said reactorvessel, said regenerator vessel for combusting carbon from thecarbonized catalyst with an oxygen-containing gas to provide regeneratedcatalyst; a regenerated catalyst conduit in communication with saidregenerator; said regenerated catalyst conduit intersecting said riserat a regenerated catalyst conduit intersection for transportingregenerated catalyst to said riser; a carbonized catalyst conduit incommunication with said reactor vessel, said carbonized catalyst conduitintersecting said riser at a carbonized catalyst conduit intersectionfor transporting carbonized catalyst to said riser; a baffle in saidriser below said feed distributor and proximate to one of saidregenerated catalyst conduit intersection and said carbonized catalystconduit intersection for mixing the carbonized catalyst and theregenerated catalyst.
 10. The apparatus of claim 9 wherein said baffleis a regenerated catalyst baffle proximate to said regenerated catalystconduit intersection and further including a carbonized catalyst baffleproximate to the said carbonized catalyst conduit intersection.
 11. Theapparatus of claim 9 wherein said regenerated catalyst conduit defines aregenerated catalyst inlet to said riser and said carbonized catalystconduit defines an carbonized catalyst inlet to said riser said baffleis disposed above one of said regenerated catalyst inlet and saidcarbonized catalyst inlet.
 12. The apparatus of claim 9 wherein saidbaffle is an extension of one of said regenerated catalyst conduit andsaid carbonized catalyst conduit into the riser.
 13. The apparatus ofclaim 9 wherein said regenerated catalyst conduit intersection is abovesaid carbonized catalyst conduit intersection.
 14. The apparatus ofclaim 9 wherein said regenerated catalyst conduit and said carbonizedcatalyst conduit define a horizontal angle of at least about 135 degreesat respective ones of said regenerated catalyst conduit intersection andsaid carbonized catalyst conduit intersection.
 15. The apparatus ofclaim 9 wherein said regenerated catalyst conduit and said riser definea vertical angle of about 25 to about 35 degrees at the carbonizedcatalyst conduit intersection.
 16. The apparatus of claim 9 wherein ahorizontal component of said baffle extends into the riser by at leastone-half of the diameter of the riser.
 17. An apparatus for mixingregenerated catalyst and carbonized catalyst for contact with ahydrocarbon feed, said apparatus comprising: a riser in which saidhydrocarbon feed is contacted with catalyst particles to catalyticallycrack hydrocarbons in said hydrocarbon feed to produce a gaseous productof lighter hydrocarbons and carbonized catalyst; a feed distributor fordistributing hydrocarbon feed to said riser; a reactor vessel incommunication with said riser, said reactor vessel for separating thecarbonized catalyst and the gaseous product; a regenerator vessel incommunication with said reactor vessel, said regenerator vessel forcombusting carbon from the carbonized catalyst with an oxygen-containinggas to provide regenerated catalyst; a regenerated catalyst conduit incommunication with said regenerator; said regenerated catalyst conduitintersecting said riser at a regenerated catalyst conduit intersectionbelow said feed distributor, said regenerated catalyst conduit fortransporting regenerated catalyst to said riser; and a carbonizedcatalyst conduit in communication with said reactor vessel, saidcarbonized catalyst conduit intersecting said riser at a carbonizedcatalyst conduit intersection below said feed distributor, saidcarbonized catalyst conduit for transporting carbonized catalyst to saidriser; wherein said regenerated catalyst conduit and said carbonizedcatalyst conduit define a horizontal angle of at least about 135 degreesat respective ones of said regenerated catalyst conduit intersection andsaid carbonized catalyst conduit intersection.
 18. The apparatus ofclaim 17 wherein said regenerated catalyst conduit intersection is abovesaid carbonized catalyst conduit intersection.
 19. The apparatus ofclaim 17 wherein said carbonized catalyst conduit and said riser definea vertical angle of about 25 to about 35 degrees at the carbonizedcatalyst conduit intersection.